2 X 65 MW CO-GENERATION CAPTIVE POWER PROJECT

CONVEYOR PACKAGE
OWNER GACL-NALCO ALKALIES & CHEMICAL PVT. LTD.

OWNER'S CONSULTANT DESEIN PRIVATE LIMITED

EPC CONTRACTOR M/s. ISGEC HEAVY ENGINEERING LIMITED.

SUB-CONTRACTOR  - M/s KAVERI
ISGEC DWG.NO. ES0153-75440100-DBR-0003 REV. 1
SUB - CONTRACTOR'S -  REV. - 
DESIGN BASIS REPORT FOR DUST SUPPRESSION SYSTEM 
DWG/DOC TITLE
WITH SPRAY CHART

PURPOSE FOR APPROVAL / FOR INFORMATION 

[Revision Status for Owner's Submission]

  

1 31-Jan-19 REVISED INTERNALLY PM RYD KPS

 0 5-Oct-18 FIRST ISSUE PM RYD KPS
PREP. CHECKED APPD.
REV.NO. DATE DESCRIPTION
BY BY BY
 ISGEC;
DRY FOG DUST SUPPRESSION SYSTEM & SPRINKLING SYSTEM FOR
2X65MW CO-GEN CAPTIVE POWER PLANT AT GACL-NALCO ALKALIES
& CHEMICALS PVT. LTD.

PREPD CHEKD DATE ISSUED FOR APPROVAL REV. TOTAL No. OF

P.B. A.K.R. 15.03.2019 1 SHEET - 18

PROJECT GACL-NALCO ALKALIES & CHEMICALS PVT. LTD.

OWNER:
ISGEC HEAVY ENGINEERING LIMITED

KAVERI ULTRA POLYMERS P LIMITED

VENDOR
DOC NO. K/DBR/JOB-18545 /102 REV. NO. : 1

TITLE DESIGN BASIS REPORT FOR DRY FOG DUST SUPPRESSION SYSTEM AND
SPRINKLING SYSEM
 DESIGN BASIS REPORT FOR DFDS SYSTEM &
SPRINKLING SYSTEM
K/DBR/JOB-18545/102 R-1

CONTENTS

1.0 INTRODUCTION

2.0 DESIGN BASIS AND WRITE UP FOR DRY FOG DUST SUPPRESSION SYSTEM &
SPRINKLING SYSTEM

3.0 CAPACITY, HEAD AND MOTOR POWER CALCULATION OF PUMPS AND

COMPRESSOR

3.1 DRY FOG DUST SUPPRESSION SYSTEM (DFDS)

3.2 SPRINKLING SYSTEM (SPS)

4.0 SCHEDULE OF MAIN EQUIPMENTS

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1.0 INTRODUCTION

The purpose of this document is to give general information about dry fog dust suppression

systems and sprinkling system along with detailed description about each system proposed for the

GACL-NALCO ALKALIES & CHEMICALS PVT. LTD.

DUST SUPPRESSION SYSTEM AND UTILITY SYSTEM:-

1) Dry Fog Dust suppression System (DFDS)

2) Sprinkling System (SPS)

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DUST SUPPRESSION SYSTEM AND UTILITY SYSTEM:-

DRY FOG DUST SUPPRESSION SYSTEM (DFDS):-
Following application points have been considered for Dry Fog Dust Suppression System (DFDS-1):-
Sl No. Location Application Point
1 Receipt & Discharge of Belt feeder BF-1A
2 Receipt at Conv. BC-1 from Belt Feeder BF-1A
RECLAIM HOPPER
3 COMPLEX-1 Receipt & Discharge of Belt feeder BF-1B
4 Receipt at Conv. BC-1 from Belt Feeder BF-1B
5 Receipt at Conv. BC-2 from vibrating Feeder VF-1D, VF-1E & VF-1F
RECLAIM HOPPER
COMPLEX-2
6 Receipt at Conv. BC-2 from vibrating Feeder VF-1A, VF-1B & VF-1C
7 Discharge of Conv. BC-2
JT-1
8 Receipt at Conv. BC-1 from Conv. BC-2
9 Discharge of Conv. BC-1
10 JNT-2 Receipt at Conv. BC-1A from Conv. BC-1
11 Receipt at Conv. BC-3 from Conv. BC-1
12 Discharge of Conv. BC-1A
13 CRUSHER HOUSE CRH-1 Receipt at Reversible Belt Feeder RBF-1 from Conv. BC-1A
14 Discharge of Reversible Belt Feeder RBF-1 (Both End)
15 Discharge of Conv. BC-3
JNT-3
16 Receipt at Conv. TBC-1 from Conv. BC-3
17 Discharge of Conv. BC-4
JNT-4
18 Receipt at Conv. BC-5 from Conv. BC-4
DESIGN CONSIDERATION FOR DRY FOG DUST SUPPRESSION SYSTEM:-
Following points have been considered while designing the system: -
i. Designed the dry fog dust suppression (DFDS) system for the locations stated above and spray chart is enclosed.
ii. Moisture retention with the material will be maximum 0.1% with this DFDS system.
iii. Dust control system within work zone shall be 2 mg/ m³ in closed area and 5 mg/ m³ in open area from over &
above ambient dust level within 3m radius from application point.
iv. The spray application point mainly receipt & discharge points from conveyor, belt feeder & Vibrating feeders
are to be modified and cover with MS plate enclosure/ rubber sheet to achieve better performance of dust
control by ISGEC.
v. Considered the entire stream will work simultaneously, accordingly air & water consumption have been
estimated and pump and compressor capacity is designed accordingly.
vi. Considered all the belt conveyors width and capacity as per specification & shown the spray chart.
vii. DFDS system for all the transfer houses shall be controlled thru. manually as well as automatically.
viii. ISGEC shall provide continuous supply of clean water at an adequate pressure at PVC tank located near the
pump house (PMH-2) as specified at the overall plot plan.
ix. Considered 2 nos. Vertical centrifugal Pump (1 Working + 1 Standby) along with motor and other accessories for
the DFDS system. One no. Duplex strainer is considered at the common suction of the pump.
x. Considered 2 nos. air cooled, oil lubricated, screw compressor (1Working + 1Standby) for the DFDS system along
with one no air receiver of capacity of 1 m³ located outside of the pump house (PMH-2).
xi. All necessary valves and instruments are provided as per system requirement. Valve size upto 50 NB shall be of
GM body and for 65 NB and above shall be of CI body. The same is shown in the P&I Diagram.
xii. ERW, GI, Heavy grade pipe & fitting as per IS1239 P-I & II is considered for Air and Water pipeline.

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xiii. Considered one no. MCC at the pump house PMH-2 for Dust suppression system. ISGEC shall provide 415 V AC
supply at the MCC further distribution of power and control supply to pumps, compressors and instruments
within the pump house PMH-2 shall be done by Kaveri.
xiv. ISGEC shall supply 230 V AC supply at each transfer tower and further distribution of control supply to field
equipment shall be done by Kaveri.
xv. Kaveri shall provide under belt switch for auto operation, however ISGEC shall supply necessary signal from Belt
feeder and vibrating feeder for auto operation.
xvi. Control voltage is considered 230 V AC for field instruments and Solenoid valve.
xvii. Underground MS pipe line shall be protected with 2mm thk. wrapping tape as per IS-10221 and Hume pipe shall
be laid for pipe protection at road crossing if any by ISGEC.

DESIGN PRINCIPLE FOR DRY FOG SYSTEM

The system has been designed using Dry fog technology to suppress dust by adding negligible percentage of moisture.
Our whole system is entirely independent area wise and automatically operated by the latest technology based consists
of the following main equipments: -
i. Flow Control Unit (FCU): FCU will be operated Local/ Remote mode. Local mode will be operated at site, Remote
mode operated through Con. Load conditions & pressure switch signal. We shall be provided provision of PLC for
operation through existing PLC (if any) in FCU. It activates flow of Air & Water through inbuilt Solenoid Valve. The
FCU comprises Solenoid Valves, Pressure Switch and Pressure Gauges to activate flow of Air & Water and to
measure the out let pressure of Air & water so as to avoid excess water due to low air pressure. Flexible hose shall
be provided for connection of FCU to air and water line. Water and air regulator shall also be provided in each way
to control the water & air pressure.
ii. Depending on material flow, dust generation, moisture content in the material, type & quantity of nozzles are
considered. There is one or more headers may be fitted in each Spray application point depending on various
criteria. One or more nozzles are fitted at each header to produce fog at dust generating zone.
iii. We use a specially designed Nozzle, entirely suitable for Dry-Fog type dust suppression system. Various types of
Nozzles have been using at different application points depending on types of dust, size, moisture addition, amount
of dust generation, temperature of flow material, etc.
iv. Considered ERW, GI, Heavy grade pipe & fitting as per IS1239 P-I & II for Air and Water pipeline. Both the pipe line
shall be laid through Conveyor gallery or over ground/underground as required.

PUMPING SYSTEM OPERATING PRINCIPLE:

• The system considered to operate manually as well as automatically.
• The pump shall be started by MCC located at pump house PMH-2 & necessary power connection shall be given
by ISGEC.
• One level switch shall be provided in the water tank for all the system.
• Pumping operation will be controlled with intermediate level and Low level.
• Water will re-circulate to water tank thru pressure release valve, when there is a small demand of water for the
system.
• Duplex Strainer with differential pressure switch is considered at suction line of pump inlet.
• Necessary Gate Valve, Globe Valve, NRV, Pressure Gauge & Pressure switch are considered in pumping system.

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UTILITY CONSUMPTION FOR DRY FOG DUST SUPPRESSION SYSTEM (DFDS):-

Water Consumption of DSN-3 Nozzle = 18 LPH

Water Pressure at each Nozzle = 1-2 Kg/cm²
Air Consumption of DSN-3 Nozzle = 3 CFM
Air Pressure at each Nozzle = 4-5 Bar
Total No. of DSN-3 Nozzle = 100 Nos.
Total No. of DSN-3 Nozzle working = 58 Nos.
Total Water Consumption = 1044 LPH
Total Water Consumption = 1.044 m³/hr.
Considering 10% margin over water consumption = 1.1484 m³/hr.
Total Air consumption = 174 CFM
Considering 10% margin over air consumption = 191.4 CFM
Selected Pump Capacity (1W+1S) = 1.5 m³/hr.
Selected compressor Capacity (1W+1S) = 195 CFM
Recommended Air Receiver Capacity = 1 M³
Recommended Tank Capacity = 2 M³

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HEAD LOSS CALCULATION FOR DFDS SYSTEM

For calculation friction loss, William Hazens formula (F) has been considered from PH to different paths.
Friction factor from William Hazens Formula (F)
F = (V/(0.85xCx((D/1000)/4)^0.63))^1.85 (Ref. pump handbook by lgor J. Karassik,
Warren Fraser of Worthington Pump Inc.
Section-9, Page 9-28, Equation No.17)
F = Friction Factor (min/m of pipe)
Q = Flow in pipe (m3/hr)
D = Diameter of pipe (m)
COF = Co-efficient of friction
C = 100
Actual
Sl. Length Flow Considered Velosity Friction Total
No. From To (m) m³/hr Dia. (NB) (m/s) loss/m Friction loss
1 Tank Suction 10 1.5 25 0.8493 0.0738 0.738
Recirculation
2 Discharge 10 1.5 20 1.3270 0.2186 2.186
Point
Recirculation
3 TP 20 1.044 20 0.9236 0.1118 2.237
Point
4 TP CRH-1 110 1.044 20 0.9236 0.1118 12.301
5 CRH-1 JT-4 210 0.18 15 0.2831 0.0175 3.684
6 CRH-1 JT-2 125 0.612 20 0.5414 0.0416 5.204
7 JT-2 JT-3 120 0.18 15 0.2831 0.0175 2.105
8 JT-2 JT-1 82 0.432 15 0.6794 0.0886 7.266
9 JT-1 RH-1 25 0.396 15 0.6228 0.0754 1.886
10 JT-1 RH-2 100 0.252 15 0.3963 0.0327 3.269

Friction loss for Path-1:- PH TP (4.423 MWC) CRH-1 (12.301 MWC) JT-4 (3.684 MWC) = 20.408
MWC
Total Friction Loss for path -1:-
Sl. Friction loss due to pipe Fittings loss (10% Loss at Pump Total loss 10% margin
(MWC) of friction loss) House (MWC) (MWC)
1 20.408 2.041 3 25.448 27.993

Head Loss Calculation for path-1:-

Case Path Head Loss due to Elevation Pressure head required Pressure head
friction (MWC) Difference(MTR) at NOZZLE INLET(MWC) required at tapping
point
1 PMH-2 JT-4
27.993 42 20 89.993

Friction loss for Path-2:- PH TP (4.423 MWC) CRH-1 (12.301 MWC) JT-2 (5.204 MWC) JT-3
(2.105 MWC) = 24.033 MWC

Total Friction Loss for path -2:-

Sl. Friction loss due to pipe Fittings loss (10% Loss at Pump Total loss 10% margin
(MWC) of friction loss) House (MWC) (MWC)
1 24.033 2.403 3 29.436 32.380

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Head Loss Calculation for path-2:-

Case Path Head Loss due to Elevation Pressure head required Pressure head
friction (MWC) Difference(MTR) at NOZZLE INLET(MWC) required at tapping
point
1 PMH-2 JT-3
32.380 15 20 67.380

Friction loss for Path-3:- PH TP (4.423 MWC) CRH-1 (12.301 MWC) JT-2 (5.204 MWC) JT-1
(7.266 MWC) RH-1 (1.886 MWC) = 31.080 MWC

Total Friction Loss for path -3:-

Sl. Friction loss due to pipe Fittings loss (10% Loss at Pump Total loss 10% margin
(MWC) of friction loss) House (MWC) (MWC)
1 31.080 3.108 3 37.188 40.906

Head Loss Calculation for path-3:-

Case Path Head Loss due to Elevation Pressure head required Pressure head
friction (MWC) Difference(MTR) at NOZZLE INLET(MWC) required at tapping
point
1 PMH-2 RH-1
40.906 15 20 75.906

Friction loss for Path-4:- PH TP (4.423 MWC) CRH-1 (12.301 MWC) JT-2 (5.204 MWC) JT-1
(7.266 MWC) RH-2 (3.269 MWC) = 32.463 MWC

Total Friction Loss for path -4:-

Sl. Friction loss due to pipe Fittings loss (10% Loss at Pump Total loss 10% margin
(MWC) of friction loss) House (MWC) (MWC)
1 32.463 3.246 3 38.709 42.580

Head Loss Calculation for path-4:-

Case Path Head Loss due to Elevation Pressure head required Pressure head
friction (MWC) Difference(MTR) at NOZZLE INLET(MWC) required at tapping
point
1 PMH-2 RH-2
42.580 15 20 77.580

From the above 4 paths, it is observed that the highest head loss in Path-1 i.e from Pump House to JT-4 i.e 89.993
MWC
Maximum Head loss in the system is = 89.993 MWC
Hence, selected head = 90 MWC
Motor shaft power calculation:-
Pump capacity selected (Q) = 1.5 m³/hr.
Pump head selected (H) = 90 MWC
Pump efficiency (n) = 40 % **
BKW = 9.81 x Q x H = 9.81 x 1.5 x 90
3600 x ƞ 3600 x 0.4
= 0.919 KW

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Considering 10% margin = 1.011 KW

Motor selected = 1.1 KW (2 pole) **

**Note:-
Efficiency & Motor rating shall be finalized after selection of pump.

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COMPRESSED AIR FOR SERVICE AIR SYSTEM (DFDS)

AIR COMPRESSOR PRESSURE DROP CALCULATION
PIPE SIZING & PRESSURE LOSS FORMULA AS PER INDUSTRIAL PIPEWORK
For Compressed Air Pipe sizing
Q/R = A.V
Therefore d = (4Q/3600x3.14VR)½ x 1000 (as per Industrial Pipework by D.N.W. Kentish)
d = ID of pipe in mm
Q = Vol of free air in M³/hr.
V= Velocity of air in m/sec = 10 m/sec
R = Ration of compression = ((gauge Pr. + Atmos. Pr) / Atmost. Pr)
7.91
Pressure drop (SI Unit) = KLQ²/Rd (as per industrial pipe work by D.NW. Kentish)
K = Constant = 800
L= Total equvt. Length of pipe in m
Q = Volume of free air in (dm³/S) (1M³=1000 dm³)
Pressure Drop Calculation:-

Sl. R= Selected Pressure

Length Flow Velocity Actual
No From To Compression Pipe Size Drop (P)
(m) m³/hr m/s Velocity
. ratio (NB) bar

Compress Air
1 10 331.74 10 40
or House Receiver 7.91 0.0277 9.2753
Air
2 TP 20 331.74 10 40
Receiver 7.91 0.0555 9.2753
3 TP CRH-1 110 297.54 10 7.91 40 0.2454 8.3191
4 CRH-1 JT-4 210 51.30 10 7.91 20 0.5487 5.7373
5 CRH-1 JT-2 125 174.42 10 7.91 32 0.3127 7.6199
6 JT-2 JT-1 82 123.12 10 7.91 32 0.1022 5.3787
7 JT-2 JT-3 120 51.30 10 7.91 20 0.3135 5.7373
8 JT-1 RH-1 25 112.86 10 7.91 20 0.3161 12.6221
9 JT-1 RH-2 100 71.82 10 7.91 20 0.5121 8.0322

Friction loss for Path-1:- Compressor TP (0.0832 bar) CRH-1 (0.2454 bar) JT-4 (0.5487 bar) = 0.877
bar
Friction Loss Path-1:-
Loss at
Fitting Loss Total loss
Friction loss due to pipe (bar) Pump 10% Margin
(10 %) (bar) (bar)
House
0.877 0.088 0.1 1.065 1.171
Pressure Required at Path-1:-
Path Pr. Loss Due to Exit Pr. Total Pressure
From To friction (bar) Required (bar) Required (Bar)
Compressor JT-4 1.171 5 6.171

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Friction loss for Path-2:- Compressor TP (0.0832 bar) CRH-1 (0.2454 bar) JT-2 (0.3127 bar)
JT-1 (0.1022 bar) RH-1(0.3161 bar) = 1.060 bar
Friction Loss Path-2:-
Loss at
Fitting Loss Total loss
Friction loss due to pipe (bar) Pump 10% Margin
(10 %) (bar) (bar)
House
1.060 0.106 0.1 1.266 1.392

Pressure Required at Path-2:-

Path Pr. Loss Due to Exit Pr. Total Pressure
From To friction (bar) Required (bar) Required (Bar)
Compressor RH-1 1.392 5 6.392

Friction loss for Path-3:- Compressor TP (0.0832 bar) CRH-1 (0.2454 bar) JT-2 (0.3127 bar)
JT-1 (0.1022 bar) RH-2(0.5121 bar) = 1.153 bar
Friction Loss Path-3:-
Loss at
Fitting Loss Total loss
Friction loss due to pipe (bar) Pump 10% Margin
(10 %) (bar) (bar)
House
1.467 0.147 0.1 1.714 1.885

Pressure Required at Path-3:-

Path Pr. Loss Due to Exit Pr. Total Pressure
From To friction (bar) Required (bar) Required (Bar)
Compressor RH-2 1.885 5 6.885

Friction loss for Path-4:- Compressor TP (0.0832 bar) CRH-1 (0.2454 bar) JT-2 (0.3127 bar)
JT-3 (0.3153 bar) = 0.955 bar
Friction Loss Path-1:-
Loss at
Fitting Loss Total loss
Friction loss due to pipe (bar) Pump 10% Margin
(10 %) (bar) (bar)
House
0.955 0.095 0.1 1.150 1.265

Pressure Required at Path-4:-

Path Pr. Loss Due to Exit Pr. Total Pressure
From To friction (bar) Required (bar) Required (Bar)
Compressor JT-3 1.265 5 6.265

From the above 4 nos. Of paths, it is observed that the highest head loss in Path-3 i.e from Compressor to RH-2 i.e
6.885 bar

Hence, Considered pressure rating of Air Compressor = 7 bar

Requirement of compressed Air = 195 CFM

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DSS-1 SPRINKLING SYSTEM FOR UNCRUSHED COAL AND LIGNITE:-

Uncrushed Coal stockpile (UCS-1) - 95 M (L) X 24 M (W) X 6 M (H)-1 No.
Uncrushed Coal stockpile (UCS-2) - 161 M (L) X 24 M (W) X 7.5 M (H)-1 No.
Uncrushed Lignite stockpile (LG-1) - 95 M (L) X 15 M (W) X 5 M (H)-1 No.
DESIGN CONSIDERATION:-
i) The sprinkling system is nothing but an artificial rain and purpose of this system to wet the entire top surface so
that micron size dust particle cannot be emission from Stock Yard due to wind velocity. The addition of water
will depends on various factors like seasonal atmosphere nature of material, wind velocity, etc. hence, duration
of sprinkling and No. of cycle shall be depends on various factors.
ii) The Sprinklers are to be fixed on both side of Stock Yard (UCS-1 & 2) and one side of Stock Yard (LG-1) at 1-1.5
meters height on ground level. 2Nos. part circle sprinklers will work simultaneously from one stockpile (one
sprinkler for each side of stock Yard UCS-1 & 2 and two nos. sprinklers for 1side of Stock Yard LG-1) & will
operate 6-8 minutes duration (generally) sequentially. After completion of sprinkling at 1st stock pile, sprinkling
of 2nd stock pile shall be operated sequentially in the same fashion and after completion of 2nd stockpile, 3rd
stockpile will work in the same fashion.
iii) Each sprinkler can be operated manually as well as through local control panel located near the stockpile area.
iv) In the auto mode 2 Nos. Part Circle Sprinklers will operate in both sides of a stockpile sequentially with a
programming logic through a local control panel placed at stockyard area. After completion of sprinkling at 1st
stock pile, 2nd stock pile & 3re stockpile will start for operation periodically. After completion of one cycle of all
three stock yards, next cycle will be started after a pre-fixed time or suit to weather conditions.
v) The system shall be operated manually as well as automatically through sequential timer.
vi) For auto operation, 1 No. solenoid valve, 1 No. globe valve & gate Valve for bypass arrangement shall be
provided in each sprinkler.
vii) Sprinkler risers will be supported with structural support of 1 to 2 meters. height on PCC foundation.
viii) Considered part circle sprinkler with capacity of 210 lpm each at a discharge pressure of 4.5 Bar and throw
radius of 20 mtrs. is considered.
ix) ISGEC shall provide continuous supply of clean water at an adequate pressure at RCC tank located near the
pump house (PMH-1) as specified at the overall plot plan.
x) Considered 2 nos. (1 Working + 1Standby) Horizontal Centrifugal Type Pump along with motor and other
accessories is considered for the Stockpile sprinkling system at pump house PMH-1.
xi) All necessary valves and instruments are considered as per system requirement. Valve size upto 50 NB shall be
of GM body and for 65 NB and above shall be of CI body. The same is shown in the P&I Diagram.
xii) Duplex Strainer with differential pressure switch is considered at the common suction line of the pumps.
xiii) All necessary Pressure gauge, Pressure switch, Differential pressure switch, Level switch is considered as per
system requirement.
xiv) ERW, MS, Heavy grade pipe & fitting as per IS1239 P-I & II is considered or pipeline.
xv) Considered one no. MCC at the pump house PMH-1 for Dust suppression system. ISGEC shall provide 415 V AC
supply at the MCC further distribution of power and control supply to pumps and instruments within the pump
house PMH-1 shall be done by Kaveri.
xvi) ISGEC shall supply 230 V AC supply at Local control panel located near the stockyard and further distribution of
control supply to field equipment shall be done by Kaveri.
xvii) Control voltage is considered 230 V AC for Solenoid valve.
xviii) Underground MS pipe line shall be protected with 2mm thk. wrapping tape as per IS-10221 and Hume pipe shall
be laid for pipe protection at road crossing if any by ISGEC.

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PUMPING SYSTEM OPERATING PRINCIPLE:-

• The system considered to operate manually as well as automatically.
• The pump shall be started by MCC located at pump house PMH-1 & necessary power connection shall be given
by ISGEC.
• One level switch shall be provided in the water tank for all the system.
• Pumping operation will be controlled with intermediate level and Low level.
• Water will re-circulate to water tank thru pressure release valve, when there is a small demand of water for the
system.
• Duplex Strainer with differential pressure switch is considered at suction line of pump inlet.
• Necessary Gate Valve, Globe Valve, NRV, Pressure Gauge, Pressure switch is considered in pumping system.

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UTILITY CONSUMPTION FOR SPRINKLING SYSTEM:-

Total No. Of Sprinklers = 28 Nos.

No. Of sprinklers working at a time = 2 Nos.
Water requirement for each Sprinkler = 210 LPM
Working pressure at each Sprinkler = 4.5 Kg/cm²
Water Requirement for one Sprinkler = 12.6 M³/hr.
Total Water Requirement for Sprinkling system = 25.2 M³/hr.
Considering 10% mergin over exact consumption = 27.72 M³/hr.
Selected Pump Capacity = 28 M³/hr.

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HEAD LOSS CALCULATION FOR SPRINKLING SYSTEM

For calculation friction loss, William Hazens formula (F) has been considered from PH to different paths.
Friction factor from William Hazens Formula (F)
F = (V/(0.85xCx((D/1000)/4)^0.63))^1.85 (Ref. pump handbook by lgor J. Karassik,
Warren Fraser of Worthington Pump Inc.
Section-9, Page 9-28, Equation No.17)
F = Friction Factor (min/m of pipe)
Q = Flow in pipe (m3/hr)
D = Diameter of pipe (m)
COF = Co-efficient of friction
C = 100
Actual
Sl. Length Flow Considered Velosity Friction Total Friction
No. From To (m) m³/hr Dia. (NB) (m/s) loss/m loss
1 Tank Suction 10 28 100 0.9908 0.0195 0.195
Recirculation
2 Discharge 10 28 80 1.5481 0.0578 0.578
Point
Recirculati
3 TP 15 25.2 65 2.1106 0.1306 1.959
on Point
4 TP JT-2 20 25.2 65 2.1106 0.1306 2.612
5 JT-2 JT-1 85 25.2 65 2.1106 0.1306 11.102
6 JT-1 RH-1 25 25.2 65 2.1106 0.1306 3.265
7 RH-1 END-1 100 25.2 65 2.1106 0.1306 13.061
8 JT-1 RH-2 100 25.2 65 2.1106 0.1306 13.061
9 RH-2 JP-2 25 25.2 65 2.1106 0.1306 3.265
10 JP-2 END-2 100 12.6 50 1.7834 0.1299 12.985
11 TP JT-3 120 25.2 65 2.1106 0.1306 15.673
12 JT-3 END-3 180 12.6 50 1.7834 0.1299 23.374

Friction loss for Path-1:- PH TP (2.537 MWC) JT-2 (2.612 MWC) JT-1 (11.102 MWC) RH-1
(3.265 MWC) END-1 (13.061 MWC) = 32.577 MWC
Total Friction Loss for path -1:-
Sl. Friction loss due to pipe Fittings loss (10% Loss at Pump Total loss 10% margin
(MWC) of friction loss) House (MWC) (MWC)
1 32.577 3.258 3 38.834 42.718
Head Loss Calculation for path-1:-
Case Path Head Loss due to Elevation Pressure head required Pressure head
friction (MWC) Difference(MTR) at NOZZLE INLET(MWC) required at tapping
point
1 PMH-1 END-1
42.718 5 45 92.718

Friction loss for Path-2:- PH TP (2.537 MWC) JT-2 (2.612 MWC) JT-1 (11.102 MWC) RH-2
(13.061 MWC) JP-2 (3.265 MWC) END-2 (12.985 MWC) = 45.562 MWC

K/DBR/JOB-18545/102R-1 Page 15 of 18
 DESIGN BASIS REPORT FOR DFDS SYSTEM &
SPRINKLING SYSTEM
K/DBR/JOB-18545/102 R-1

Total Friction Loss for path -2:-

Sl. Friction loss due to pipe Fittings loss (10% Loss at Pump Total loss 10% margin
(MWC) of friction loss) House (MWC) (MWC)
1 45.562 4.556 3 53.118 58.430
Head Loss Calculation for path-2:-
Case Path Head Loss due Elevation Pressure head required Pressure head
to friction Difference(MTR) at NOZZLE INLET(MWC) required at tapping
(MWC) point
1
PMH-1 END-2 58.430 5 45 108.430

Friction loss for Path-3:- PH TP (2.537 MWC) JT-3 (15.673 MWC) END-3 (23.374 MWC) = 41.584
MWC

Total Friction Loss for path -3:-

Sl. Friction loss due to pipe Fittings loss (10% Loss at Pump Total loss 10% margin
(MWC) of friction loss) House (MWC) (MWC)
1 41.584 4.158 3 48.742 53.616
Head Loss Calculation for path-3:-
Case Path Head Loss due Elevation Pressure head required Pressure head
to friction Difference(MTR) at NOZZLE INLET(MWC) required at tapping
(MWC) point
1
PMH-1 END-3 53.616 5 45 103.616

From the above 3 paths, it is observed that the highest head loss in Path-2 i.e from Pump House to END-2 i.e
108.43 MWC
Maximum Head loss in the system is = 108.43 MWC

Hence, selected head = 110 MWC

Motor shaft power calculation:-

Pump capacity selected (Q) = 28 m³/hr.
Pump head selected (H) = 110 MWC
Pump efficiency (n) = 60 % **
BKW = 9.81 x Q x H = 9.81 x 28 x 110
3600 x ƞ 3600 x 0.6

= 13.980 KW
Considering 10% margin = 15.378 KW
Motor selected = 18.5 KW (4 pole) **

**Note:-
Efficiency & Motor rating shall be finalized after selection of pump.

K/DBR/JOB-18545/102R-1 Page 16 of 18
 DESIGN BASIS REPORT FOR DFDS SYSTEM &
SPRINKLING SYSTEM
K/DBR/JOB-18545/102 R-1

SCHEDULE OF PUMP & COMPRESSOR FOR DUST SUPPRESSION SYSTEM

MOTOR
SL PUMP QUANTITY
SYSTEM CAPACITY UNIT HEAD UNIT RATING APPLICATION
NO. HOUSE (NOS.)
(KW)**
1 DFDSP-1A/1B 1.5 m³/hr. 90 mwc 1.1 DFDS SYSTEM 1W+1S
PMH-2
2 DFDSC-1A/1B 195 CFM 7 bar 30 DFDS SYSTEM 1W+1S
DSS-1A/1B SPRINKLING
3 PMH-1 28 m³/hr. 110 mwc 18.5 1W+1S
SYSTEM

**Note:-
Efficiency & Motor rating shall be finalized after selection of pump.

K/DBR/JOB-18545/102R-1 Page 17 of 18
CLIENT:- ISGEC DATE:-5/9/2019
PROJECT:-NALCO DAHEJ

SPRAY CHART NALCO DAHEJ

Spray Flow Rate Flow Rate Flow Rate Flow Rate Compressor Compressor Compressor Compressor
BELT BELT NOZZLE QTY. Working at a time Flow Rate Compressor
SL. NO. Application Point Bar @18 LPH m³/hr 20LPH m³/hr @3.0 CFM m³/hr. @7CFM m³/hr. REMARKS
WIDTH CAP. m³/hr per TH m³/hr. TH
1
DSN 3 DSN 6 DSN 3 DSN 6 DSN 3 DSN 3 DSN- 6 DSN 6 DSN 3 DSN 3 DSN-6 DSN 6
For DFDS-1
Sl No. Location Application Point
1 Receipt & Discharge of Belt feeder BF-1A 1000 150 4 4 0 0 0.000 0 0.000 0 0.000 0 0.000
2 RECLAIM Receipt at Conv. BC-1 from Belt Feeder BF-1A 800 300 7 7 0 0 0.000 0 0.000 0 0.000 0 0.000
HOPPER 0.000 0.000 2W (20X15)
3 Receipt & Discharge of Belt feeder BF-1B 1000 150 4 4 0 0 0.000 0 0.000 0 0.000 0 0.000
COMPLEX-1
4 Receipt at Conv. BC-1 from Belt Feeder BF-1B 800 300 7 7 0 0 0.000 0 0.000 0 0.000 0 0.000
5 RECLAIM Receipt at Conv. BC-2 from vibrating Feeder VF-1D, VF-1E & VF-1F 800 300 7 7 7 126 0.126 0 0.000 21 35.910 0 0.000 1W (20X15)
HOPPER 0.252 71.820
6 COMPLEX-2 Receipt at Conv. BC-2 from vibrating Feeder VF-1A, VF-1B & VF-1C 800 300 7 7 7 126 0.126 0 0.000 21 35.910 0 0.000 1W (20X15)
7 Discharge of Conv. BC-2 800 300 3 3 3 54 0.054 0 0.000 9 15.390 0 0.000
JT-1 0.180 51.300 1W (20X15)
8 Receipt at Conv. BC-1 from Conv. BC-2 800 300 7 7 7 126 0.126 0 0.000 21 35.910 0 0.000
9 Discharge of Conv. BC-1 800 300 3 3 3 54 0.054 0 0.000 9 15.390 0 0.000
10 JNT-2 Receipt at Conv. BC-1A from Conv. BC-1 800 300 7 7 0 0 0.000 0 0.000 0.180 0 0.000 0 0.000 51.300 3W (20X15)
11 Receipt at Conv. BC-3 from Conv. BC-1 800 300 7 7 7 126 0.126 0 0.000 21 35.910 0 0.000
12 Discharge of Conv. BC-1A 800 300 3 3 3 54 0.054 0 0.000 9 15.390 0 0.000
CRUSHER HOUSE
13 Receipt at Reversible Belt Feeder RBF-1 from Conv. BC-1A 800 300 8 8 8 144 0.144 0 0.000 0.252 24 41.040 0 0.000 71.820 3W (20X15)
CRH-1
14 Discharge of Reversible Belt Feeder RBF-1 (Both End) 800 300 6 6 3 54 0.054 0 0.000 9 15.390 0 0.000
15 Discharge of Conv. BC-3 800 300 3 3 0 0 0.000 0 0.000 0 0.000 0 0.000
JNT-3 0.000 0.000 1W (20X15)
16 Receipt at Conv. TBC-1 from Conv. BC-3 800 300 7 7 0 0 0.000 0 0.000 0 0.000 0 0.000
17 Discharge of Conv. BC-4 800 300 3 3 3 54 0.054 0 0.000 9 15.390 0 0.000
JNT-4 0.180 51.300 1W (20X15)
18 Receipt at Conv. BC-5 from Conv. BC-4 800 300 7 7 7 126 0.126 0 0.000 21 35.910 0 0.000
100 100 0 58 0 1044 1.044 0 0.000 1.044 174 297.54 0 0.00 297.540

Water requirement for DFDS-1 = 1044 LPH Air requirement for DFDS-1 = 174 CFM ………….1
1.044
= M3/hr. Considered 10% margin = 191.4 CFM
Total consumtion =1.044 M3/hr. Recommended Compressor Capacity = 195 CFM (min) at a pressure 7 Kg/cm²
Considered 10% margin =1.1484 M3/hr.
Recommended pump Capacity (1W+1S) = 1.5 M3/hr.

Page 18 of 18